Method of Preparing Nickel Titanium Alloy for Use in Manufacturing Instruments with Improved Fatigue Resistance

ABSTRACT

A method of treating Nitinol to train the structure thereof to remain in the martensite state, including the steps of subjecting the Nitinol to a strain and while subjected to the strain, thermally cycling the Nitinol between a cold bath of about 0° C. to 10° C. and a hot bath of about 100° C. to 180° C. for a minimum of about five cycles.

REFERENCE TO PENDING APPLICATIONS

This application is not related to any pending domestic or internationalpatent applications.

REFERENCE TO MICROFICHE APPENDIX

This application is not referenced in any microfiche appendix.

BACKGROUND OF THE INVENTION

I. Field of the Invention

The present invention is related generally to a method of treating anickel titanium alloy, known as Nitinol, for use in manufacturinginstruments having improved resistance to cyclic fatigue failure. As aparticular application, the invention is related to preparation ofNitinol wire blanks for use in manufacturing endodontic files havingimproved resistance to cyclic fatigue failures.

2. Background of the Invention

Many medical applications take advantage of the properties of Nitinol, anickel and titanium alloy. Nitinol (an acronym for Nickel Titanium NavalOrdinance Laboratory) exhibits several useful properties such as shapememory, by which a Nitinol component returns to a previously memorizedshape after being forced into a second shape. Nitinol also exhibitssuperelasticity, meaning that a Nitinol component may be deformedelastically to a very large extent by strain without reducing itsability to return to the its original shape after the strain has beenremoved. One drawback of Nitinol, however, is that in certainconfigurations it is not very resistant to fatigue, i.e. repeated cyclicstrains.

The present invention is directed to a method of preparing Nitinol sothat it can be used to manufacture instruments that retain themartensitic state at the operating temperature with correspondinggreater resistance to cyclic fatigue failure.

The present invention is further directed to a method of forming adental device comprising the steps of forming the device of Nitinolhaving an impressed memorized shape, wherein the memorized shape is ashape the element assumes when in an operational configuration. Theelement is treated so that it is substantially martensite phasestabilized under expected operating conditions.

Nitinol is an alloy which was developed to achieve improved elasticityand other enhanced mechanical properties. Nitinol also possesses shapememory properties that are well suited for medical and dentalapplications. Elements constructed of Nitinol may be formed in a first“memorized” shape to which they will return after deformation. That is,when such a Nitinol element has been deformed, raising a temperature ofthe element above a critical temperature causes the element to revert toits memorized shape.

As would be understood by those of skill in the art, Nitinol alloys canexist in one of two different temperature-dependent crystal structures.At lower temperatures, Nitinol is martensitic, meaning that itsstructure is composed of self-accommodating twins, in a zigzag-likearrangement. Martensite is soft and malleable, and can be easilydeformed by de-twinning the structure via application of strain. Athigher temperatures, above a critical temperature of the alloy, Nitinolis austenitic. Austenite is a strong and hard phase of the alloy,exhibiting properties similar to those of titanium, and is characterizedby a much more regular crystalline lattice structure. Nitinol alloys canalso undergo a phase change as a result of the application of a strain.For example, an element in the austenitic phase can be bent so that athigh strain locations the alloy becomes martensitic. If the alloy isdesigned to have an unstable martensite phase at the operatingtemperature, removal of the strain results in a reverse transformationthat straightens the bending.

3. Description of the Prior Art

For background information relating to the subject matter of thisinvention, reference may be had to the following issued United Statespatents and publications:

PATENT NUMBER INVENTOR(S) ISSUE DATE TITLE 5,464,362 Heath et al. Nov.07, 1995 Endodontic Instrument 5,762,541 Heath et al. Jun. 09, 1998Endodontic Instrument 5,984,679 Farzin-Nia et al. Nov. 16, 1999 Methodof Manufacturing Superelastic Endodontic Files and Files Made Therefrom6,149,501 Farzin-Nia et al. Nov. 21, 2000 Superelastic EndodonticInstrument, Method of Manufacture, and Apparatus Therefor 6,315,558Farzin-Nia et al. Nov. 13, 2001 Method of Manufacturing SuperelasticEndodontic Files and Files Made Therefrom 6,428,317 Abel Aug. 06, 2002Barbed Endodontic Instrument 6,431,863 Sachdeve et al. Aug. 13, 2002Endodontic Instruments Having Improved Physical Properties 6,626,937 CoxSep. 30, 2003 Austenitic Nitinol Medical Devices 2003/0199236 Aloise etal. Oct. 23, 2003 Method of Manufacturing An Endodontic Instrument2004/0171333 Aloise et al. Sep. 02, 2004 Method of Manufacturing AnEndodontic Instrument 2004/0193104 Jervis Sep. 30, 2004 Bendable,Reusable Medical Instruments With Improved Fatigue Life 2004/0216814Dooley et al. Nov. 04, 2004 Shape Memory Alloy Articles With ImprovedFatigue Performance and Methods Therefore 2005/0059994 Walak et al. Mar.17, 2005 Fatigue Resistant Medical Devices 2005/0090844 Patel et al.Apr. 28, 2005 Long Fatigue Life Nitinol

BRIEF SUMMARY OF THE INVENTION

The present invention relates to manufacturing methods of achievingimprovements in the fatigue resistance of Nitinol instruments. Themethods involve thermal and mechanical rearrangement and stabilizationof a cold-working-induced martensite state in Nitinol instruments, suchthat the Nitinol parts are in a martensitic state thermodynamically atoperating temperatures, with the characteristic austenite finishtemperature of the Nitinol metal, measured by a differential scanningcalorimeter, being above the part's operating temperature and in whichthe ultimate tensile strength to upper plateau stress ratio in a tensiletest is 2.8 or higher. A series of fatigue performance tests haveindicated that the improved martensitic Nitinol wire blanks andinstruments made therefrom, have useable lives up to seven times longerthan the conventional austenitic ones under the same operatingconditions.

Fatigue fracture is a common problem in endodontic instruments.Improvements in fatigue resistance of Nitinol is desirable since itprovides increased fatigue life and better fatigue life predictability.Existing methods have not adequately addressed the effects of Nitinolprocessing on fatigue life and fatigue life improvements have beenlimited to a relatively small range (generally less than 50%improvement). The present invention provides a novel method to increasethe useable life of endodontic instruments by as much as seven times.

The starting material for use in the method of this invention is aNitinol composition consisting of 55.8+/−1.5 wt. % nickel (Ni);44.2+/−1.5 wt. % titanium (Ti); and trace elements including iron (Fe),chromium (Cr), copper (Cu), cobalt (Co), oxygen (O), hydrogen (H),and/or carbon (C), generally less than 1 wt. % each.

The invention is practiced by starting with Nitinol in an austeniticstate. This material is 45+/−5% cold worked (cross-sectional areareduction) at finish diameter followed by final straightening anneal at500 to 600° C. for 60 to 120 seconds. With the material in themartensitic state it is 35+/−5% cold worked at a finished diameter. Itis then subjected to final straightening anneal at 400 to 475° C. for120 to 300 seconds and then thermal cycled under constraint elongationof 1 to 4% between cold (0 to 10° C.) and hot (100 to 180° C.) for 3 to5 times.

The resultant material then has a tensile modulus as follows: Austeniticconditions: Average ˜10 Mpsi and Martensitic conditions: Average ˜6 Mpsi(“Mpsi” meaning “million pounds per square inch”).

The material also has the ultimate tensile strength to the upper plateaustress ratio as follows: Austenitic conditions: Average ˜2.5; andMartensitic conditions: Average ˜3.0. The austenite finish temperatureas measured by a differential scanning calorimeter is an average ˜15° C.and the martensite finished temperature measured in the same way is anaverage ˜52° C.

Nitinol wire blanks tested at room temperature in austenitic conditionsaveraged 83.5 seconds to fracture while, employing the same testprocedures, in martensitic conditions the Nitinol wire blanks averaged562.4 seconds to fracture, thus an approximately 700% improvement.

Endodontic files tested at 37° C. (body temperature) under austeniticconditions averaged 85.7 seconds to fracture while with the same test,under martensitic conditions the files averaged 261 seconds to fracture,thus a greater than 300% improvement.

A more complete understanding of the invention will be obtained from thefollowing detailed description of the preferred embodiments and claims,taken in conjunction with the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevational view of a typical endodontic file showing thelower portion thereof, that is, the stem of the file havingcircumferential grooves formed on the outer surface to formcircumferential cutting/scraping edges. The invention herein is a methodof providing a Nitinol alloy having improved resistance to fatiguefailure. The file of FIG. 1 is illustrated as an example of a medicaldevice that can be successfully manufactured by employing Nitinolmaterial produced by practicing the invention herein.

FIG. 2 is an elevational cross-sectional view of a molar human toothshowing the root system and the coronal area penetrated by a hole toexpose the root canal system. Shown positioned within one of the rootcanals is the endodontic file as illustrated in FIG. 1. The endodonticfile is subjected to substantial bending and torsional stress as it isused in the process of cleaning and shaping a root canal. The inventionherein is concerned with the material of which the endodontic file ismade to significantly increase resistance to cyclic fatigue.

FIG. 3 is a diagrammatic illustration of steps employed in practicingthe invention here to treat Nitinol wire so that it can be employed forproducing instruments having greatly improved resistance to cyclicfatigue.

FIG. 4 illustrates diagrammatically the transitions of Nitinol betweenaustenite and martensite phases in response to changes in temperatureand deformation.

FIG. 5 is a graph illustrating the hysteresis effect as Nitinol istransitioned between martensite and austenite phases.

FIG. 6 shows diagrammatically the changes in phases of Nitinol inresponse to changes in temperature and stress as is shown in FIG. 4 butin somewhat greater detail.

FIG. 7 illustrates an example of cold working procedures that can beemployed in preparing Nitinol wire for the final manufacturing steps asshown in FIG. 3.

FIG. 8 is a diagrammatic representation of a test machine standconstructed to test the fatigue resistance of Nitinol material,particularly Nitinol material in the form of wire of the type commonlyused in the manufacture of instruments including endodontic files.

FIG. 9 is a diagrammatic representation of another set up for testingthe cyclic fatigue of a finished endodontic file as being representativeof products made from Nitinol material utilizing the principles of thepresent invention. FIG. 9 shows a Nitinol endodontic file subjected to abending fatigue test.

FIG. 10 is a cross-sectional view as taken along the line 10-10 of FIG.9 showing the relationship of the components employed in the fatiguetest of FIG. 9 and showing the position of the endodontic file beingtested.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

It is to be understood that the invention that is now to be described isnot limited in its application to the details of the construction andarrangement of the parts illustrated in the accompanying drawings. Theinvention is capable of other embodiments and of being practiced orcarried out in a variety of ways. The phraseology and terminologyemployed herein are for purposes of description and not limitation.

Elements illustrated in the drawings are identified by the followingnumbers:

10 Endodontic file 12 Shaft portion 14 Proximal end 16 Handle 18 Distalend 20 Tooth    22 A, B Roots 24 Hole 26 Crown 28 Roll of Nitinol wirein Austenite form 30 Nitinol wire 32 Cold water shower 34 Cold watertank 36 First turn wheel 38 Second turn wheel 40 Third turn wheel 42 Hotwater tank 44 Fourth turn wheel 46 Treated wire 48 Finish spool 50Austenite form 52 Twinned martensite form 54 Deformed martensite 56Nitinol austenite state 57 Nitinol deformed austenite state 58 Nitinoltwinned martensite state 60 Nitinol deformed martensite state 62 Spoolof Nitinol wire 64 Untreated Nitinol Wire 66 Annealing oven 68 Die 70Die 72 Die 74 Die 76 Wire holding clamp 78 Test machine stand 80 Nitinolwire 82 Wheel 84 Axis 86 Dowel pins 88 Mandrel 90 Deflection block 92Arcuate surface 94 Space 96 Groove 98 Rotating instrument holder 100 Chuck 102  Endodontic instrument 104  Nozzle 106  Water or air

FIGS. 1 and 2 illustrate an endodontic file. An endodontic file is agood example of a product that is subject to fatigue failure and whereina failure of the product is a serious event. Thus the endodontic file isillustrated as an example of a product that can be successfullymanufactured by the methods of this invention. FIG. 1 is an elevationalview of an endodontic file generally indicated by the numeral 10 thathas an elongated shaft portion 12 with a proximal end 14 to which issecured a small cylindrical handle 16, normally made of plastic by whichthe file shaft portion 12 can be inserted into and removed from the rootcanal of the tooth. The handle 16 is configured to be positioned betweenthe thumb and forefinger of an endodontist to facilitate manipulation ofthe file in the root canal and simultaneously rotation of the file. Thedistal end 18 of file 10 is of reduced diameter compared to the proximalend and is typically pointed.

FIG. 2 illustrates a typical tooth 20, in this case is a molar, havingplural roots 22A and 22B, that in a healthy tooth are filled with pulpalmaterial. When this pulpal material becomes infected the tooth is deemedto be abscessed and the pressure generated by the abscess causes anintense tooth ache. Endodontists treat this malady by performing a rootcanal procedure in which the root canals 22A and 22B are cleaned ofpulpal material. To do that a hole 24 is drilled in the tooth crown 26to provide access to the root canals 22A and 22B. An endodontist insertsa file 10 through the hole 24 into the canals to facilitate removal ofthe pulpal material. FIG. 2 shows the tooth free of pulpal material.

The endodontic tool 10 of FIGS. 1 and 2 is, as previously stated, anexample of a type of instrument that requires a high degree offlexibility along with resistance to torque fatigue. It can be seen thatif in the process of treating a root canal 22A a lower portion of dentalfile 10 is broken off in the canal then the endodontist is faced with aserious problem, particularly if the root canal beneath the broken offportion has not been thoroughly cleaned of infected pulpal material. Itis therefore important in manufacturing endodontic files to providefiles that have great flexibility and at the same time high fatigueresistance.

It is important to understand that the endodontic file shown in FIGS. 1and 2 and the use thereof is by example only to establish the need forstructural material for use in constructing the shaft portion 12 toachieve high flexibility and, most importantly, high fatigue resistance.It is important to understand that the invention herein does not concernendodontic files per se but concerns methods of treating material, andparticularly treating an alloy to produce a metal having idealcharacteristics for use in the manufacture of endodontic tools and othersimilar medical and non-medical devices that require high fatigueresistance.

It has been learned that an ideal material for manufacturing toolsrequiring flexibility and fatigue resistance is an alloy of nickel andtitanium. This alloy is commonly referred to in industry as “Nitinol”.The expression “Nitinol” will be used herein rather than“nickel/titanium alloy”. The preferred composition of Nitinol is about55.8%, +/−1.5%, by weight of nickel combined with 44.2%, +/−1.5%, byweight of titanium. In addition to these two primary components of thealloy, trace elements including iron (Fe), chromium (Cr), copper (Cu),cobalt (Co), oxygen (O), hydrogen (H), carbon (C) are typicallyincluded, the trace elements generally totaling less than about 1% byweight of the finished alloy.

Nitinol as an alloy exists in two naturally occurring forms, that is, inthe austenite form and in the martensite form. FIG. 5 is a graph showingtransitions that occur in Nitinol as the form of the metal changesbetween austenite and martensite. As illustrated in this graph, within agiven temperature range, the alloy can stabilize as either martensite oraustenite. The graph in FIG. 5 shows that starting from a giventemperature designated as martensite finish temperature “M_(f)”, as thetemperature increases the point is reached where the austenite formstarts, designated as austenite start temperature “A_(s)”. The austeniteform increases as a percent of the alloy rapidly as the temperatureincreases to the austenite finish state, designated as austenite finishtemperature A_(f). The alloy will remain in the 100% austenite form evenas the temperature increases to a temperature indicated as M_(d) whichis the highest temperature at which strain induced martensite can exist.It is an essential aspect of the present invention that Nitinol in themartensite form can demonstrate significantly improved fatigueresistance.

The invention is practiced by starting with Nitinol in an austeniticstate. This material is 45+/−5% cold worked followed by finalstraightening anneal at 500 to 600° C. for 60 to 120 seconds. With thematerial in the martensitic state it is 35+/−5% cold worked at afinished diameter. It is then subjected to final straightening anneal at400 to 475° C. for 120 to 300 seconds and then thermal cycled underconstraint elongation of 1 to 4% between cold (0 to 10° C.) and hot (100to 180° C.) for 3 to 5 times. The resultant material then has a tensilemodulus as follows: Austenitic conditions: Average ˜10 Mpsi andMartensitic conditions: Average ˜6 Mpsi. The material has an ultimatetensile strength as follows: Austenitic conditions: Average ˜2.5; andMartensitic conditions: Average ˜3.0. The austenite finish temperatureas measured by a differential scanning calorimeter is an average ˜15° C.and the martensite finished temperature measured in the same way is anaverage ˜52° C.

As previously stated, FIG. 5 is a graph illustrating a typical phasechange temperature hysteresis curve for Nitinol. The austenite phase inthe alloy is plotted as a function of the temperature, with severalimportant transition temperatures marked. A_(s) indicates thetemperature at which the austenite starts and A_(f) indicates thetemperature wherein the alloy is 100% in the austenite phase, that is,the austenite transition is finished. M_(s) and M_(f) indicate themartensite start and finish temperatures, that is where the transitionto martensite starts and finishes. It is apparent that the twotransformations do not occur at the same temperature. Rather, ahysteresis loop exists corresponding to the phase transformation. Inaddition, a M_(d) temperature exists, indicating the highest temperatureat which strain induced martensite can exist, i.e., the temperatureabove which martensite can not be induced by strain. “Strain”, “stress”and “deformation” are used interchangeably in this context. As would beunderstood by those skilled in the art, the specific temperatures atwhich Nitinol transitions occur are very sensitive to small variationsin the alloy's content of nickel, titanium and any other trace elements.Nitinol's properties thus can be tailored for specific applications bycontrolling the alloy's composition. However, manipulation of Nitinolalloy content is not a subject of this invention.

FIG. 4 diagrammatically illustrates the transition of Nitinol betweenthe austenite form and the martensite form. The upper box 50 showsdiagrammatically the arrangement of atoms of the alloy in an orderlyfashion in which the alloy is in the austenite form. As the temperatureof the alloy cools, the atomic structure changes from the initialorderly structure to a twinned martensite arrangement as shown in thelower left box 52. In this twinned martensite form and without asignificant change in temperature, the alloy can be subject todeformation, particularly caused such as by stretching, so that it istransformed into a state indicated as “deformed martensite” or“de-twinned martensite” indicated by the lower right box 54. The alloycan remain in such state until heat is applied to reach the level of theaustenite start (A_(s)) as shown in FIG. 5. As further heat is appliedthe alloy will then return to the 100% austenite state.

The shape memory and superelasticity properties of Nitinol may beunderstood in terms of the phase transformations the alloy undergoesunder various conditions. As described above, shape memory refers to theability to restore an originally memorized shape of a deformed Nitinolsample by heating it. FIG. 4 is a graph of temperature versusdeformation illustrating the shape memory effect. An austenitic alloyelement 50 has a shape represented by block 50 entitled “AUSTENITE” at atemperature above the A_(f) temperature. The alloy is heated to atemperature above the A_(f) temperature and formed into this desiredshape. This causes the alloy to memorize the desired shape. As thetemperature is lowered below the M_(s) temperature, the alloy moves tothe condition represented by the block 52 entitled “TWINNED MARTENSITE”.If a strain is applied to the alloy element to deform it will take thecondition identified by block 54 entitled “DEFORMED MARTENSITE” and willretain its shape even after the deformation inducing strain has beenremoved. Then, if the alloy is again heated to a temperature above theA_(f) temperature, a thermoelastic phase transformation takes place andthe element returns to its memorized, AUSTENITE shape of block 50regaining its strength and rigidity.

An essential aspect of this invention is a system and method fortransforming otherwise austenitic Nitinol, such as can occur in the formof wire, into a semi-stable martensite form. When in such martensiteform the alloy can be manufactured into an implement, such as, byexample, an endodontic file as illustrated in FIGS. 1 and 2.

FIG. 3 illustrates a method of this invention of training Nitinol wireto retain the martensite state which may also be referred to as a“de-twinned martensite” state. In FIG. 3, a roll of Nitinol wire isindicated by the numeral 28. The Nitinol wire 30 passes through a coldwater shower 32 that exists over a cold water tank 34. The wire 30 afterpassing through the shower 32 and being cooled to the temperature ofabout 0° C. to 10° C., passes over a first turn wheel 36 and bends overa second turn wheel 38. The wire 30 travels horizontally to a thirdwheel 40. Between wheels 38 and 40 wire 30 moves through hot water tank42 wherein the temperature of the water is about 100° C. to 180° C. Outof the tank the wire 30 passes over a fourth turn wheel 44 to repeat theprocess.

From turn wheel 44 wire 30 passes back again through cold water shower32, over first turn wheel 36, second turn wheel 38, through hot watertank 42, passed third turn wheel 40 and back again over fourth turnwheel 44. Wire 30 repeats this route a plurality of times, andpreferably about four (4) or five (5) times. Thus, as shown in FIG. 3,the wire 30 from reel 28 is cycled four or five times between cold watershower 32 at about 0° C. to 10° C. and hot water tank 42 at about 100°C. to 180° C. After making four or five passages through the cold watershower and hot water tank the treated wire 46 passes to a finish spool48. Wire from finish spool 48 is then in condition to be used tomanufacture products, specifically instrumentation or other productsthat require a high degree of flexibility combined with an unusuallyhigh fatigue resistance characteristic.

Referring again to FIG. 4, the austenite atomic arrangement isillustrated in block 50. This illustration is diagrammatic and intendedto be pictorial and is only representative of the form of the Nitinolwhen in the austenite state. When the austenite form 50 of FIG. 4 iscooled, the form of the Nitinol alloy takes an atomic arrangement termedthe twinned martensite as indicated by block 52. When the Nitinol wireis in the twinned martensite form 52 and is subjected to deformation,particularly to stretching, the deformed martensite takes an atomicstructure pictorially represented by block 54. Therefore, referring backto FIG. 3, it is important that the wire 30 be subjected to adeformation as it makes about four or five loops around wheels 36, 38,40 and 44. Such deformation is most easily achieved by the applicationof strain on the wire of between 1 to 10%. This can be achieved byapplying torque to finish spool 48. Thus, as wire 30 passes through thecold water shower 32 and hot water tank 42 approximately four or fivetimes, it is constantly under tension deformation. Thus the Nitinol wirewound onto finish spool 38 is in the deformed martensite state.

Shape memory and superelasticity of Nitinol are associated withreversible martensitic transformation. This transformation isillustrated in FIG. 4. When the martensite is thermally formed due tocooling it consists of a micro-twinning structure as represented by form52. Under proper stress or strain conditions the micro-twinningstructure undergoes a de-twinning or a realignment process to achieve anenergetically stable martensitic state. The micro-twinning andde-twinning process may occur concurrently during the thermal cyclingprocess as shown in FIG. 3. This thermal cycling process illustrated inFIG. 3 can also be called “training”. Under this process which includesa constant 1 to 10% strain the de-twinning and realignment results in astabilized martensitic structure with reduced interfacial friction andresidual deformation. This contributes to the greatly improved fatigueresistance that is accomplished according to the processes of thisinvention.

FIG. 6 is a diagram illustrating the temperature versus deformationcharacteristics of Nitinol. Nitinol has a characteristics of attaining amemorized state indicated by the arrangement of atoms. As shown in FIG.6, when the temperature of the Nitinol is decreased the atomic structuregoes into the twinned martensite state as represented by the numeral 58.While in this reduced temperature state deformation can cause atransformation to a state pictorially illustrated by the numeral 60which has been defined as the deformed martensite state or de-twinnedmartensite state.

Again referring to FIG. 6, this diagram illustrates temperature versusdeformation showing the superelasticity property of Nitinol. Asdiscussed above with reference to FIG. 5, an alloy element has a shapethat is memorized in a state 56 above the critical temperature in whichstate the alloy is austenitic. This critical temperature is between theM_(s) and the M_(d) temperatures. When a strain is applied to the alloyelement, the element is deformed to the state 57 in which the alloyelement contains large areas of strain-induced martensite. These areasoccur primarily at locations at which the highest levels of strain areinduced and result in severe deformation that may be unrecoverable.However, at temperatures at which martensite is not the stable phase ofthe alloy, as soon as the strain is removed, the alloy reverts to anaustenitic state 56 and returns to the memorized shape. Superelasticitythus refers to this ability of these alloys while in the austeniticstate, to revert to an original shape after severe deformation understrain.

FIG. 7 illustrates the steps normally employed to convert a Nitinol wireinto a stable martensite state useable for manufacturing fatigueresistant devices. From a spool 62, such as would be supplied by amanufacturer of Nitinol alloy products, untreated Nitinol wire 64 passesthrough an annealing oven 66 and then through a series of dies 68, 70,72 and 74 to a final heat thermal process. From the final heat thermalprocess the wire can be placed on a spool, such as spool 28 as seen inFIG. 3. The wire on spool 28 is then in condition for use in thede-twinning or alignment process of FIG. 3. After going through themicro-twinned alignment process of FIG. 3, the wire on finish spool 48is then in condition for use in manufacturing components or tools, suchas the endodontic files that require flexibility and fatigue resistance.

Nitinol treated according to the principles of this invention remains inthe martensitic phase even when raised to a temperature above theotherwise critical operating temperature. Therefore, applying additionalstrain to the alloy does not tend to result in a phase change. Rather,additional strain simply results in a deformation of the alloy whichremains in the martensitic phase. The damaging irreversible straininduced from austenite to martensite phase transformation does not takeplace, and the life of the Nitinol element is substantially increased.In addition, the alloy in the martensite phase is more soft andmalleable than when in the austenite phase. Thus martensitic alloy hasreduced incidences of stress concentration thereby contributing to theimproved fatigue resistance characteristics of the material.

As described above, the shape memory and superelasticity properties ofNitinol and other similar alloys particularly suit them for use inmanufacturing medical and dental instruments. The shape memory is usefulas it allows an instrument to convert from a first shape to a memorizeddeployed configuration after being warmed above a critical operatingtemperature (e.g. by body heat) while superelasticity is useful to allowthe instrument to greatly deform while under severe stress in the body,and still return to its original shape.

Nitinol alloy is generally designed to be in the austenitic phase at itsoperating temperature (i.e., at body temperature), and to be in themartensitic phase at some lower, relatively easy to maintaintemperature. The invention herein teaches a method of training a Nitinolinstrument to stay in the martensitic phase at body temperature tothereby achieve substantially improved resistance to cyclic fatigue.Specifically, it is desired to improve the fatigue life of Nitinolalloys under conditions where strains (particularly repeated strains)imparted thereto are sufficient to cause phase transformation fromaustenite to martensite. In addition, it is desired to reduce theformation of fatigue cracks which tend to initiate at the material'sstress concentration locations under bending conditions which may occurin a medical device. This is particularly beneficial in the applicationof Nitinol in the manufacture of endodontic files.

According to the embodiments of the present invention, Nitinol devicesare provided that exhibit an increased resistance to fatigue, whileretaining their shape memory and superelastic properties. The Nitinolalloy devices according to the invention have an increased ability towithstand cyclic strains, such as may be experienced, for example, inthe use of an endodontist file to clean and shape a tooth root canal.Since the Nitinol devices made according to this invention are treatedso they tend to remain in the martensitic phase even when the device isat a temperature above the critical operating temperature, applyingadditional strain does not tend to result in a phase change. Rather,additional strain simply result in the deformation of the alloy while itremains in the martensitic phase. Damaging irreversible strain inducedfrom austenite to martensite phase transformation do not easily takeplace with Nitinol treated according to the methods of this invention.

To verify the integrity of the principles of this invention and toauthenticate that by practicing the method of treating Nitinol drawnwire, the structure of which has been trained according to theprinciples of this invention to remain in the martensite state and tothereby achieve improved fatigue resistance, a test stand as exemplifiedin FIG. 8 was created. The test stand provides a wire holding clamp 76that is supported by a test machine stand 78. Secured within wireholding clamp 76 is a length of trained Nitinol wire 80 that has beentreated according to the process of this invention. The length of thewire 108 was taken from treated wire 46 as seen in FIG. 3 which isobtained at the conclusion of the manufacturing process as describedherein. In this test wire 80 is about 2 inches long and is of a gauge ofthe type frequently employed for manufacturing endodontic instruments,such as about 1.0 millimeters in diameter.

Rotatably supported to test machine stand 78 if a wheel 82 that rotatesabout an axis 84. Extending from the face of wheel 82 are two dowel pins86A and 86B. The dowel pins are typically about one-fourth inch indiameter.

Wheel 82 rotates in a plane which is parallel to the plane of Nitinolwire 80 and in a manner so that the dowel pins 86A and 86B strike thewire and deflect it each time the wheel rotates. In the test utilizingthe test stand of FIG. 8, wheel 82 was rotated at a rate of 336 rpm.Since there are two dowel pins 86A and 86B, wire 80 was therebydeflected 672 times a minute. After a dowel pin passes, the wire springsback by its inherent resiliency to extend straight down as indicated inFIG. 8. In summary, the test stand of FIG. 8 deflected the wire 672times per minute.

Using the test stand of FIG. 8, first a wire that is characterized bythe austenitic condition, that is, that had not been subjected to thetraining procedures of the invention herein as described was testedunder room temperature conditions. The wire having austenitic conditionfailed on the average after about 935 deflections whereas a wire 106having martensitic conditions as trained by the techniques of thisinvention on average failed after about 6299 deflections, thusdemonstrating the significant fatigue resistance obtained by the methodof treating Nitinol drawn wire by this invention.

Referring now to FIGS. 9 and 10, a system is illustrated that wasdesigned to test endodontic files to measure fatigue resistance. Thetest stand of FIG. 9 illustrates diagrammatically a grooved mandrel thatis 12 millimeters in diameter. Positioned adjacent the perimeter ofmandrel 88 is a deflection block 90 having an arcuate surface 92concentric to and spaced from the perimeter of mandrel 88. FIG. 10 showsthe relationship between the deflection block 90 and the perimeter ofmandrel 88 providing a space 94 therebetween. Mandrel 88 has on theperipheral surface a shallow depth groove 96 as seen in FIG. 10.

Supported near deflection block 90 is a rotating instrument holder 98that has a chuck 100 by which the proximal portion of the shaft of anendodontic instrument 102 can be secured.

Positioned adjacent deflection block 90 is a nozzle 104 that is employedto eject a temperature control medium, such as warm water or compressedair 106 onto endodontic instrument 102. The cyclical fatigue testemploying the set up as shown in FIGS. 9 and 10 were conducted whereinthe temperature of instrument 102 was maintained wet with warm water atabout 37° C., that is about body temperature, to approximate thetemperature conditions when an endodontic file is utilized as to cleanand shape the root canal of a human tooth. In these tests the endodonticinstrument was rotated, that is, spinning counterclockwise at 300 rpm.Rotation of endodontic instrument 102 was continued until it broke as aresult of bending fatigue. With instrument 102 having Nitinol austeniticcondition the average time to breakage was 85.7 seconds whereas with theinstrument being formed of Nitinol having martensitic conditions andhaving been subjected to the training techniques of this invention ashas been described and illustrated, the average time of the breakage was261 seconds. Thus, utilizing essentially the same Nitinol material firstin austenitic condition and then in trained martensitic condition, thefatigue resistance was about three times greater at a testingtemperature of 37° C., thus showing a substantial improvement in fatigueresistance by employing the principles of this invention for a toolintended to be utilized at body temperature.

The tests performed as indicated by FIGS. 8, 9 and 10 were not intendedto measure improvements in fatigue resistance under all conceivableconditions, but have been carried out sufficient to graphicallydemonstrate the significant improvement in fatigue resistance of Nitinolmaterial when a martensitic condition is maintained employing thetraining and principles of the invention as illustrated and describedherein.

While the invention has been described with a certain degree ofparticularity, it is manifest that many changes may be made in thedetails of construction and the arrangement of components withoutdeparting from the spirit and scope of this disclosure. It is understoodthat the invention is not limited to the embodiments set forth hereinfor purposes of exemplification, but is to be limited only by the scopeof the attached claim or claims, including the full range of equivalencyto which each element thereof is entitled.

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 12. A flexible instrument comprising an elongated metallic element that is subject to lateral and torsional stress as used and in which the instrument is stabilized in an induced martensitic phase that persists under pre-determined working temperatures and exemplifies substantially improved fatigue resistance.
 13. A flexible instrument according to claim 12 wherein said metallic element is formed of a nickel/titanium alloy.
 14. A flexible instrument according to claim 13 wherein said nickel/titanium alloy is Nitinol.
 15. A flexible instrument according to claim 12 in which the instrument is stabilized by being subjected to thermal cycling a plurality of times between cold and hot baths while under deformation.
 16. A flexible instrument according to claim 15 in which the deformation is-provided by strain of between 1% and 10%.
 17. A flexible instrument according to claim 15 in which said thermal cycling includes subjecting the instrument to temperature changes between a first temperature of about 0° C. to 10° C. and a second temperature of about 100° C. to 180° C.
 18. A flexible instrument comprising: an elongated metallic shaft having proximal and distal portions; a handle portion of said proximal portion for facilitating mechanical or manual manipulation of said shaft; wherein said shaft is formed of a shape memory alloy which has been subjected to thermal cycling while under deformation to induce said shaft to maintain the martensitic phase at a body temperature range in which said shaft demonstrates significantly improved longitudinal and torsional fatigue resistance.
 19. A flexible instrument according to claim 18 wherein said metallic shaft is formed of a nickel/titanium alloy.
 20. A flexible instrument according to claim 19 wherein said nickel/titanium alloy is Nitinol.
 21. A flexible instrument according to claim 18 in which the instrument is stabilized by being subjected to thermal cycling a plurality of times between cold and hot baths while under deformation.
 22. A flexible instrument according to claim 18 in which the deformation is provided by strain of between 1% and 10%.
 23. A flexible instrument according to claim 21 in which said thermal cycling includes subjecting the instrument to temperature changes between a first temperature of about 0° C. to 10° C. and a second temperature of about 100° C. to 180° C.
 24. A medical/dental device for use in the human body, comprising: an elongated instrument formed of a binary superelastic metal alloy susceptible of different molecular phases that has been subjected to thermal cycling while under deformation to induce said instrument to maintain a selected phase at body temperatures in which said instrument demonstrates significantly improved longitudinal and torsional fatigue resistance.
 25. An elongated instrument according to claim 24 wherein said metal alloy is formed of a nickel/titanium alloy.
 26. An elongated instrument according to claim 25 wherein said nickel/titanium alloy is Nitinol.
 27. An elongated instrument according to claim 24 in which the instrument is subjected to thermal cycling a plurality of times between cold and hot baths while under deformation.
 28. An elongated instrument according to claim 24 in which the deformation is provided by strain of between 1% and 10%.
 29. An elongated instrument according to claim 27 in which the instrument is subjected to thermal cycling between a first temperature of about 0° C. to 10° C. and a second temperature of about 100° C. to 180° C.
 30. An endodontic instrument that is flexible and resistant to torsional fatigue and that is adapted for use in performing root canal therapy on a tooth, comprising: a cylindrical elongate shank composed of an alloy comprising at least about 40% titanium and at least about 50% nickel, said elongate shank further having a proximal end and an opposite distal end so as to define a working length adjacent said distal end; at least one ground flute extending helically around said shank working length and defining at least one cutting edge, a helical land positioned between axially adjacent flute segments; and said shank being trained to remain in a trained molecular state at body temperature by having been subjected to strain of between about 1% and about 10% while being thermally cycled between hot and cold baths. 